Our Sites

New aluminum forming method can cut car chassis weight in half

Members of AP&T’s R&D team are (from left) Otto Kragt (development engineer, R&D), Lars-Olof Jönsson (project manager, R&D), Knut Erik Snilsberg (MSc metallurgy, SINTEF), and Dr. Christian Koroschetz (director, technology development).

AP&T is cooperating with Raufoss Technology, Hydro Aluminium, and the SINTEF research institute to develop a new method for forming of aluminum sheet. The method will enable passenger cars to be manufactured with a significantly lower weight than today, which will enable greatly reduced fuel consumption and environmental impact.

The goal is for chassis parts currently made of steel or die-cast aluminum to be manufactured from aluminum sheet using a press hardening process. According to the company, chassis weight could be cut in half if this method were applied in new cars.

To reach this goal, a cost-efficient production process is needed that guarantees all of the parts obtain the desired strength and stability. The project members are planning to have completed a production line for test manufacturing within four years. Extensive development of materials, forming techniques, and processes remains to be completed before then.

AP&T will share its knowledge of tool and process design. The company also will be responsible for producing a full-scale production line for manufacturing test parts. One of SINTEF's metallurgists now is working on-site at AP&T in Ulricehamn, Sweden, as part of the cooperation initiative.